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SERVICE MANUAL SG-3R40 SG-3C41 SG-3D55 Ver.1.0 ©Jun. 2019 by Shimano Inc. ITP CONTENTS Introduction of INTER-3 / Explain the technologies ……………………… 2 Dealer's Manual ……………………………………………………………………………………………………………………… 3 SG-3R40, SG-3C41, SG-3D55 • INSTALLATION • MAINTENANCE Troubleshooting ……………………………………………………………………………………………………………………… 31 Disassembly & Assembly ……………………………………………………………………………………………… 33 Tools Disassembly of the Inter-3 hub (Roller Brake Spec.) Assembly of the Inter-3 hub (Roller Brake Spec.) Service Parts ………………………………………………………………………………………………………………………………… 45 Interchangeability ………………………………………………………………………………………………………………… 47 Hub dimensions ………………………………………………………………………………………………………………………… 49 EV / Spare Parts List ……………………………………………………………………………………………………………… 51 1 Return to index page SG-3R40 SG-3C41 SG-3D55 INTER-3 Rear Hub (3-speed) INTER-3 Rear Hub (3-speed) INTER-3 Rear Hub (3-speed) • Internal Gear Shifting • Internal geared hub for Coaster Brake version • Internal geared hub for Disc Brake version » Gear shifting action is independent of pedaling. • Integral Coaster Brake • Gear Change Support Mechanism You can shift gears anytime, while standing still, • Gear Change Support Mechanism • Aluminum hub shell pedaling or coasting • Weight: 1,120g • CENTER LOCK Rotor mount system • Gear Change Support • Weight: 945g • Weight: 885g • Color options: Black, Silver • Color options: Black, Silver, White TECHNOLOGIES Gear Change Support SHIMANO gear change support mechanism utilizes some portion of pedaling force at down shifting. The result is a quick and precise downshift with very light feeling. Coaster Brake The SHIMANO NEXUS coaster brake is operated by pedaling backward in a similar way as ordinary types. Its uniqueness is that braking power transmitted to the wheel directly for the SHIMANO NEXUS internal coaster brake is independent of the gear shifting mechanism built into the hub. Also it always generates the same braking force regardless of gear position to actualize comfortable and reliable riding. It actualizes the braking force to meet the ISO 4210 standard. Equal braking force in each gear Sprocket Actuator Hub shell Brake shoe Brake roller Braking cam Surface Treatment What is the difference between the Standard and the DX version? • The Standard version is designed to use under normal climate conditions. • The DX version features a clear coated finish and/or stainless steel material. This finish is offering an advanced protection against corrosion and is therefore recommended to use under more severe climate conditions. 2 Return to index page Dealer's Manual SG-3R40 SG-3C41 SG-3D55 3 Return to index page WARNING When securing the brake arm to the frame, be sure to use an arm clip that matches the size of the chainstay, and securely tighten it with the clip bolt and clip nut to the specified tightening torque. Use a lock nut with a nylon insert (self-locking nut) for the clip nut. It is recommended that Shimano made clip bolts, clip nuts, and arm clips be used. Use an arm clip that matches the chainstay. If the clip nut comes off the brake arm, or if the clip bolt or arm clip becomes damaged, the brake arm may rotate on the chainstay and cause the handlebars to jerk suddenly, or the bicycle wheel may lock and the bicycle fall over, causing serious injury. INSTALLATION Installation of the lever Installation of the REVOSHIFT lever Install the brake lever (B). (A) Brake lever band (B) Brake lever (z) Use Φ22.2 mm handlebars. (C) Handlebar (A) (B) Tightening torque 1 6 - 8 N·m (z) TECH TIPS (C) Use a brake lever with a band having a thickness of 4.3 mm or lower to prevent the brake lever and REVOSHIFT lever from interfering with each other. (A) Install the REVOSHIFT lever (A). (A) REVOSHIFT lever 2 Click here for the latest Dealer's Manual 4 https://si.shimano.com/DM/SG0005 Return to index page Install the half grip (A). (A) Half grip (B) Gap between the REVOSHIFT lever Leave a gap (B) of 0.5 mm between the and the half grip REVOSHIFT lever and the half grip. 3 (A) (B) Tighten the REVOSHIFT lever. (A) Fixing bolt Tightening torque 4 2 - 2.5 N·m 2 - 4 N·m (A) Click here for the latest Dealer's Manual 5 https://si.shimano.com/DM/SG0005 Return to index page Installation of the bell crank type hub Installation of the shifting cable (A) Insert the outer casing into the outer (A) Outer casing holder casing holder (A). 1 Fit the inner cable into the link (B) in the (A) Cable adjustment barrel bell crank. (B) Link (C) Inner cable mounting plate Loosen the inner cable mounting nut (D) (D) Inner cable mounting nut (A) on the bell crank. Pass the inner cable through the cable adjustment barrel (A) along the groove NOTICE in the link and between the link and Make sure to pass the inner cable through the 2 inner cable mounting plate (C). groove in the link. (B) (C) (D) Set the REVOSHIFT lever to 2. 3 Click here for the latest Dealer's Manual 6 https://si.shimano.com/DM/SG0005 Return to index page With the inner cable kept tight, tighten the inner cable mounting nut while positioning the end of the link between the two white lines on the window. (y) White lines (z) Position the end of the link between the white lines. 4 (y) (y) (z) After tightening the inner cable mounting nut, cut off the excess length of inner cable. (z) Within 4 mm 5 (z) Click here for the latest Dealer's Manual 7 https://si.shimano.com/DM/SG0005 Return to index page Tighten the bottom cover (B) with the (A) Bottom cover fixing screw (A) bottom cover fixing screw (A). (B) Bottom cover Tightening torque 0.4 - 0.7 N·m (SM-BC03) (B) 0.35 - 0.55 N·m 6 (SM-BC04/SM-BC06) Click here for the latest Dealer's Manual 8 https://si.shimano.com/DM/SG0005 Return to index page Installation of the sprocket to the hub (SM-GEAR) Place the right-hand waterproof cap B (A) Snap ring (A) (C) onto the driver (D) on the right side (B) Sprocket of the hub body. (C) Right-hand waterproof cap B Next, install the sprocket (B) and secure (D) Driver (B) it in place with the snap ring (A). (E) Right-hand waterproof cap A (z) Note the direction (z) (C) (D) (E) Installation of the sprocket to the hub (CS-S500 sprocket with chain guard) Install the chain guard (B) to the (A) Right-hand waterproof cap B (z) right-hand waterproof cap A (D) of the (B) Chain guard (A) hub body, and then install the right- (C) Driver hand waterproof cap B (A) to the driver (C). (D) Right-hand waterproof cap A (z) Note the direction (B) NOTICE Do not use an inward assembling sprocket with 16T or less, otherwise the right-hand waterproof cap A will come into contact with the sprocket. (C) 1 (D) (A) (B) Click here for the latest Dealer's Manual 9 https://si.shimano.com/DM/SG0005 Return to index page Install the CS-S500 sprocket (C) to the (A) Snap ring (A) driver (D) on the right side of the hub (B) Guard plate body with the guard plate (B) facing (C) CS-S500 Sprocket outward, and secure it in place with the (D) Driver (B) snap ring (A). 2 (C) (D) Click here for the latest Dealer's Manual 10 https://si.shimano.com/DM/SG0005 Return to index page Installation of the hub to the frame (for disc brakes) Install the disc brake rotor (A) to the (A) Disc brake rotor hub. (B) Disc brake rotor mounting ring (C) TL-LR10 (A) (B) (C) Tightening torque 1 40 N·m < When not using the chain tensioner > Mount the chain on the sprocket, and (A) Dropout then set the hub axle (B) into the (B) Hub axle dropout (A). 2 (A) (B) < When using the chain tensioner > Mount the chain on the sprocket, and (A) Chain tensioner then set the hub axle into the dropout. When using the chain tensioner (A), be sure to read the attached instruction manual for the CT-S500 chain tensioner. 2 (A) Click here for the latest Dealer's Manual 11 https://si.shimano.com/DM/SG0005 Return to index page (A) Place the non-turn washer (A) onto the (A) Non-turn washer left side of the hub axle from the outer (z) side. NOTICE At this time, turn the hub axle and install Use a non-turn washer that matches the the non-turn washer so that the shape of the dropout. protrusion of the washer fits into the Non-turn washer (for left side use) groove in the dropout. Dropout Mark / Color Size ϴ ≤ 20° Standard (z) The protrusion should be on the ϴ ≤ 38° 3 dropout side. Reversed 2 / Yellow ϴ = 0° Reversed (full chain ϴ = 0° Install the non-turn washer so case) Vertical 8L / Green = 60° - 90° that the protrusion fits securely in ϴ the dropout groove at the front and back sides of the hub axle. Mark Click here for the latest Dealer's Manual 12 https://si.shimano.com/DM/SG0005 Return to index page Take up the slack in the chain and secure (A) Washer (3.2 mm) the wheel to the frame, using a 3.2 mm (B) Hub nut (9 mm) washer (A) and a 9 mm hub nut (B) on the right side and a cap nut on the left side of the hub axle. Tightening torque 30 - 45 N·m NOTICE (B) (A) Make sure that the hub axle on the right side protrudes about 8 to 13 mm from the end face of the hub nut.
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